Using wireless devices based on the IEC-approved WirelessHART standard, agribusiness leader expects $25-$50K in annual raw materials savings through cost-effective monitoring of heat exchangers
AUSTIN, TEXAS (May 20, 2010) — Emerson’s Smart Wireless solution, based on the IEC 62591 (WirelessHART) standard, is allowing Syngenta Crop Protection to optimize production of weed control products by saving an expected $25,000 to $50,000 annually at its St. Gabriel, La., facility.
Syngenta selected Smart Wireless to closely monitor the heat exchangers in its plant because the secure technology can reliably deliver continuous data directly to the plant’s control room, enabling tight process control.
“It has allowed us to optimize operation of the heat exchangers to improve production,” said Mark Gauthie, Syngenta instrument technician. “We estimate that we’ll save $25,000 to $50,000 annually in raw materials cost as a result.”
Six Rosemount® DP wireless transmitters monitor cooling water flow on three reactors at the facility. The devices communicate with a Smart Wireless Gateway installed up to 800 feet from the furthest transmitter. The company had relied upon daily clipboard rounds by staff to collect data from local gauges, which sometimes resulted in inaccurate readings. When the gauges corroded in the harsh environment, Syngenta sought a cost-effective, easy-to-implement solution to supply continuous measurements to its control room.
The Smart Wireless network delivers information directly to the plant’s DeltaV™ digital automation system, eliminating the need for clipboard rounds. The company uses Emerson’s AMS™ Suite predictive maintenance software to easily manage the new devices, which enables technicians to configure them, run diagnostic checks, and monitor alarms and alerts.
Installation and commissioning of the devices, across five levels in an area congested with piping and other equipment, took about 48 hours. The installation cost for wireless was about $6,000 less than a wired solution.
“We liked the self-organizing network Smart Wireless provides,” Gauthie said. “Some transmitters are tucked in between piping or on the back side of a reactor, yet everything has worked well. The transmitters communicate with each other as well as the gateway, and we’ve had no problems.”
After realizing these production gains through Smart Wireless, Syngenta plans to expand its use.
“With the wireless gateway in place it now allows us to add additional measurement points at minimal cost,” Gauthier said. “We’ve already purchased a second gateway and temperature and level monitors to use in an additional production unit.”
Syngenta Crop Protection is a subsidiary of Syngenta Global. Headquartered in Basel, Switzerland, Syngenta Global is one of the world’s leading agribusinesses with operations in more than 90 countries.
In addition to the Smart Wireless solutions already installed at Syngenta, Emerson offers a wide range of wireless field instrumentation and plant operations equipment, including Fisher® position monitors, Rosemount Analytical and Machinery Health™ Management devices, and SmartStart™ services. Smart Wireless technology is an extension of Emerson’s PlantWeb™ digital plant architecture.